What Should You Do If Your Solar Panel Is Cracked?

By Melanie Dawn

November 16, 2024

You finally took the plunge and purchased solar panels for your home. You have the system set up, and it’s working as expected. One day, while cleaning your panels, you notice one with a crack. What now?

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Solar panels are incredibly durable and resistant to the elements and can last 25 to 30 years with proper care and maintenance. They're made from silicon, metal and tempered glass. Despite their strong construction, solar panels can become cracked due to a fallen tree branch, bad weather or too much pressure from a pressure washer.

Fortunately, you can do a few things on your own if you have a cracked solar panel.

What Happens If a Solar Panel Cracks?

Solar panels work by absorbing light rays and converting those rays into electricity. The more panels you have, the more electricity you can expect to generate. While this is not always the case, broken solar panels can disrupt the flow of electricity and cause it to not work efficiently.

If the damage to the panel is minor, it may not affect the largest area of cells. In this case, you may experience only a slight dip in production, if any.

If a Solar Panel Is Cracked, Will It Still Work?

The good news is a broken solar panel can still work as it should. Even shattered panels can work and produce high voltage amounts. In some cases, they may not work as efficiently as they should.

Just because a broken solar panel works, it doesn’t mean you should ignore the problem and continue using the panel. These cracks generate hotspots, which can overheat and start a fire on extremely hot days. In addition, if the solar panel glass has cracked, it might expose the inside of the panel to moisture and dirt. This may lead to corrosion and dirt over time.

Another issue to consider is that water penetrating the inside of the panel may cause the internal voltage to reach the outside. The voltage on the outside of the panel makes it unsafe to touch.

Can You Fix Cracked Glass on a Solar Panel?

If you’re a handyman who likes tackling home projects, you may be able to fix the cracked glass on a solar panel. However, a repair is only a temporary solution unless you replace the glass. By calling a professional, you know the job is done correctly.

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How Do You Fix a Cracked Solar Panel?

There are two ways you can repair a cracked solar panel. Neither of these solar panel crack repair methods removes the cracks, but they will prevent water and moisture from seeping into the glass. You might also look for a DIY repair kit that seals small cracks in glass. These kits may help but usually won't make the panel fully functional.

Note: The best thing you can do in this case is call a professional to help you with the repair. If you insist on going the DIY route, please take all proper precautions, as you are working with electricity and sensitive materials. Make sure (and double-check) that your solar panels are disconnected before performing any work. The following steps are merely an outline to give you an idea of the process. If you plan to do this project yourself, please consult a more comprehensive step-by-step guide.

Step 1: Laminating the Glass

One of the easiest ways to repair a cracked solar panel is by laminating the glass. All you need is a soft cloth, laminating film, a heat gun and a squeegee.

Wipe down the panel with a soft cloth to remove any dust and debris.
Cut a piece of laminating film large enough to fit over the entire glass panel.
Spread the film out over the panel.
Use a squeegee to remove any bubbles.
Hold the heat gun at least 6 inches away from the panel to fuse the sheet.

Step 2: Using Polyurethane Paint

Painting the panel is another low-cost do-it-yourself method to fix a cracked solar panel.

Pour polyurethane paint over the entire panel.
Spread the paint evenly using a squeegee tool.
Let the panel dry completely.

Before attempting to repair a cracked solar panel on your own, check with the panel manufacturer to see if it's still under warranty. You may be able to get a replacement or have the damage fixed for free. If the panel is under warranty and you don't call a professional, you may void the warranty.

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